Zavoli Alisei Instalation Manual en, Auto Gaz Zavoli Alisei, Zavoli
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GENERAL INSTALLATION
MANUAL
Ali
sei-ZETA Sequential Injection – General Installation Ma
nual
ELECTRONIC GASEOUS FUEL INJECTION
SYSTEM (LPG)
WITH “MASTER/SLAVE”FUNCTION
Retrofit System
TYPE:
Alisei-ZETA
GENERAL MANUAL
Part
I
MANUAL ID: MT_IGI-001.01.E
MANUAL REVIEWS
REV.
DATE
REVISED PARAGRAPHS
0
08/05/2007
FIRST ISSUE
1
06/10/2009
SECOND ISSUE
ZAVOLI S.r.l.
2
Verificato ed approvato dal Direttore Tecnico: DTE
 Ali
sei-ZETA Sequential Injection – General Installation M
anual
Valued Customer,
ZAVOLI srl
congratulates you on your choice. We would like to draw
your attention to some of the features of
Alisei-ZETA
’
s
LPG
or
Methane Gas
sequential gaseous fuel injection. This state of the art
injection system is the result of
ZAVOLI
’s long experience and
ongoing research in the field of LPG and Methane kits for vehicles. Our
kits can be installed in any multipoint fuel injection motor vehicles.
Thanks to its superior integration features,
Alisei-ZETA
guarantees
high performances as well as an easy, user-friendly installation process.
The following manual is designed to guide you through the
installation process and provide clear, complete information about the
installation of our system. It will help you learn how the system works
while guiding you through the details of its installation and
configuration process.
ZAVOLI srl would also like to remind you that our
Technical
Support Center
is always available for any question or problem you
might encounter during the installation of our system.
ZAVOLI S.r.l.
3
 Ali
sei-ZETA Sequential Injection – General Installation M
anual
Alisei-ZETA
RETROFIT KIT
INSTALLATION MANUAL
PART ONE
The
Alisei-ZETA
retrofit kit installation manual is divided into two sections. The first one
includes general information about the kit, while the second contains a selection of
installation charts designed for different types of vehicles.
CONTENTS
(PART ONE)
CHAPTER 1: THE
Alisei-ZETA
RETROFIT KIT - INTRODUCTION
CHAPTER 2: INSTALLATION
CHAPTER 3: STARTING PROCEDURE
CHAPTER 4: MAINTENANCE PROGRAM, TROUBLESHOOTING
CHAPTER 5: GLOSSARY OF TERMS AND ACRONYMS USED IN THE MANUAL
ZAVOLI S.r.l.
4
 Ali
sei-ZETA Sequential Injection – General Installation M
anual
TABLE OF CONTENTS
CHAPTER 1
1.
THE
Alisei-ZETA
RETROFIT KIT
–
INTRODUCTION
……7
1.1
The
Alisei-ZETA
Retrofit System
…..……………….
…………
……7
1.2
Main features of the
Alisei-ZETA
Retrofit Kit
…………………
……8
1.2.1
The
Alisei-ZETA………………………………………………….
……8
1.2.2
Reliability …………………………………………………………
……9
1.2.3
Performance……………………………………………………….
……9
1.2.4
An Environmentally-friendly System …………………………..
……9
1.3
NOTES ……………………………………………………………
……10
1.3.1
What to Do in Case of Maintenance Checks or Repairs ………
……10
1.3.2
Environmental Operating Conditions ………………………….
……10
1.3.3
After an Accident ………………………………………………...
……10
1.4
Operating Strategies of the Retrofit System ……………………
……11
1.5
General Description of the Components ……………………….
……13
1.5.1
ZETA Regulator/Vaporizer ……………………………………..
……14
1.5.2
GAS ECU ………………………………………………………....
……16
1.5.3
Gas Injectors ……………………………………………………...
……17
1.5.3.1
Matrix MJ Rail …………………………………………………...
……17
1.5.3.2
PAN Injectors …………………………………………………….
……18
1.5.4
Pressure Sensors………………………………………………….
……18
1.5.5
Gas Temperature Sensor …………………………………...........
……18
1.5.6
Pneumatic-Hydraulic Tubing Harness and Connectors ……....
……19
1.5.7
Main Wiring ……………………………………………..............
……19
1.5.8
Petrol/Gas Switch ………………………………………………..
……20
1.5.9
LPG Solenoid Valve ……………………………………………..
……20
1.5.10
Gaseous Phase Gas Filter ……………………………………….
……21
1.5.11
Tanks and Accessories …………………………………………..
……21
1.5.12
High Safety Standards …………………………………………..
……21
1.5.12.1
Watertight Chamber ……………………………………………..
……22
1.5.12.2
Interception Solenoid Valve ………………………………
……...
……22
1.5.12.3
Fuel Supply Control Cut-Off Valve …………………….............
……22
1.5.12.4
Excess Flow Valve ………………………………………………..
……22
1.5.12.5
Pressure Release Valve ………………………………………….
……22
1.5.12.6
Thermofuse ………………………………………………………
……23
CHAPTER 2
2.
INSTALLATION INSTRUCTIONS ………………...
……24
2.1
Getting Ready to Install ………………………….........................
…….24
2.2
Check-ups and Suggestions ……………………………………..
…….24
2.3
Equipment and Materials Required for the Installation ………
…….24
2.4
INSTALLATION - MECHANICAL PARTS…………………..
…….25
2.4.1
ZETA
Regulator/Vaporizer ……………………………………..
…….25
2.4.2
Tubing Connections ……………………………………. ………
…….27
2.4.3
LPG Solenoid Valve ……………………………………………..
…….28
2.4.4
Filter Units for the Gaseous Phase ……………………………..
…….28
2.4.5
Injectors…………………………………………………………..
…….28
2.4.5.1
PAN 4-Cylinder (2+2) Rail Injectors Assembly Kit ……………
…….29
2.4.5.2
PAN Rail Injectors Assembly Kit (3x1) ………………………..
…….30
ZAVOLI S.r.l.
5
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